General Information: Other Suzuki Forenza I

General Repair Instructions

If a floor jack is used, the following precautions are recommended

1. Park the vehicle on level ground, "block" the front or rear wheels, set the jack against the frame, raise the vehicle and support it with chassis stands and then perform the service operation.
2. Before performing the service operation, disconnect the negative battery cable in order to reduce the chance or cable damage and burning due to short-circuiting.
3. Use a cover on the body, the seats and the floor to protect them against damage and contamination.
4. Handle brake fluid and antifreeze solution with care as they can cause paint damage.
5. The use of proper tools, and the recommended essential and available tools where specified, are important for efficient and reliable performance of the service repairs.
6. Use genuine SUZUKI parts.
7. Discard used cotter pins, gaskets, O-rings, oil seals, lock washers angle-torqued fastener and self-locking nuts. Prepare new ones for installation. Normal function of these parts cannot be maintain if these parts are reused.
8. Keep the disassembled parts neatly in groups to facilitate proper and smooth reassembly.
9. Keep attaching bolts and nuts separated, as they vary in hardness and design depending on the position of the installation.
10. Clean the parts before inspection or reassembly.
11. Also clean the oil parts, etc. Use compressed air to make certain they are free of restrictions.
12. Lubricate rotating and sliding faces of parts with oil or grease before installation.
13. When necessary, use a sealer on gaskets to prevent leakage.
14. Carefully observe all specifications for bolt and nut torques.

When service operation is complete, make a final check to be sure service was done properly and the problem was corrected.

VIN Plate

The VIN plate is attached to the top of the driver's side of the instrument panel.

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Vehicle Lifting Procedures

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Engine

SPECIAL TOOL SPECIFICATION Substitute Special Tools Special Tools Described in This Manual SUZUKI Scan Tool (Tech 2 Kit) Scanner or Scan Tool - NOTE: This kit includes the following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loop back connector, 11. Storage case, 12. Power supply - DW110-060 Engine Assembly Support Fixture 09916-77310 J-8037 Piston Ring Compressor Universal Piston Ring Compressor - J-8087 Cylinder Bore Check Gauge - J-36972 Crankshaft Rear Oil Seal Installer - KM-135 Adapter - KM-340-0 Cutter Set 09916-14510 KM-348 Valve Spring Compressor Valve Spring Compressor - KM-412 Engine Overhaul Stand - KM-427 Piston Pin Service Set - -KM-470-B Angular Torque Gauge - KM-471 Adapter-Radiator Cap - KM-498-B Pressure Gauge - KM-571-B Gauge - KM-635 Crankshaft Rear Oil Seal Installer 09916-14521 KM-653 Attachment Adapter - KM-805 Valve Guide Reamer

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Front Suspension

FRONT SUSPENSION SPECIFICATION Substitute Special Tools Special Tools Described in This Manual - 500-20 Hex Nut - J-36661-2 Forcing Screw - J-37105-B-1 Support Bridge - J-37105-B-2 Bearing Adapter - J-37105-B-3 Hub Adapter - J-42468 Front Strut Mount Nut Wrench - KM-158 Remover / Installer 09943-25010 KM-329-A Spring Compressor Spring Compressor - KM-507-B Ball Joint Remover

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Rear Suspension

SPECIFICATION REAR SUSPENSION Substitute Special Tools Special Tools Described in This Manual - J-42468 Front Strut Mount Nut Wrench 09943-25010 KM-329-A Spring Compressor Spring Compressor

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Drive Shafts

DRIVE SHAFTS SPECIFICATION Substitute Special Tools Special Tools Described in This Manual - DW340-110 Axle Shaft Remover (For AT) General Tool J-8059 Snap Ring Pliers 09943-55010 J-35566 Boot Clamp Pliers Seal Clamp Pliers - KM-460-A Axle Shaft Remover (For MT) - KM-507-B Ball Joint Remover

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ABS

ABS SPECIFICATION Substitute Special Tools Special Tools Described in This Manual SUZUKI Scan Tool (Tech 2 Kit) Scanner or Scan Tool NOTE: This kit includes the following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loop back connector, 11. Storage case, 12. Power supply

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Automatic Transaxle / Transmission

AUTOMATIC TRANSAXLE / TRANSMISSION SPECIFICATION Substitute Special Tools Special Tools Described in This Manual SUZUKI Scan Tool (Tech 2 Kit) Scanner or Scan Tool NOTE: This kit includes the following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loop back connector, 11. Storage case, 12. Power supply - DW110-060 Engine Support Fixture - DW240-010 Universal Pressure Gauge Set - DW260-010 Transaxle Support Fixture - DW260-020 Transaxle Holding Fixture - DW260-030-01 (LH) Axle Seal Installer - DW260-030-02 (RH) Axle Seal Installer - DW260-050 Park / Neutral Position Switch Installer - DW260-060 Brake F Split Stop Ring Remover / Installer - DW260-070 Transaxle Fluid Plug Remover / Installer - DW260-080 Clutch B/E Shim Setting Gauge - DW260-090 Clutch B/E (Installation Space) Measuring Fixture - DW260-100 Clutch B/E Disc Thickness Measuring Fixture - DW260-110 Brake F Disc Clearance Measuring Bar - DW260-120 Clutch B Adjust Ring - DW260-130 Clutch E Adjust Ring - DW260-140 Clutch B Stop Ring Remover / Installer - DW260-150 Clutch E Stop Ring Remove / Installer - DW260-160 Brake C/D Snap Ring Remover / Installer

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Manual Transaxle / Transmission

MANUAL TRANSAXLE / TRANSMISSION SPECIFICATION

Clutch

CLUTCH SPECIFICATION

Steering

STEERING SPECIFICATION Substitute Special Tools Special Tools Described in This Manual 09944-36011 KM-210-A Steering Wheel Remover Steering Wheel Puller - KM-507-B Ball Joint Remover - KM-J-26610 Installer - J-42459 Rack Guide Spring Cap Wrench - KM-354-B Pressure Test Gauge Kit

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Air Conditioning System

AIR CONDITIONING SYSTEM SPECIFICATION Substitute Special Tools Special Tools Described in This Manual General Tool J-5403 Snap Ring Pliers General Tool J-6083 Snap Ring Pliers - J-8092 Driver Handle - J-8433-1 Puller Crossbar - J-8433-3 Forcing Screw - J-9398-A Bearing Remover - J-9481 Bearing Installer - J-9553-1 O-ring Remover - J-9625-A Pressure Testing Connector - J-23128-A Seal Seat Remover and Installer - J-33011 O-ring Installer - J-33013-B Hub and Drive Plate Remover and Installer - J-33017 Pulley Rotor and Bearing Installer - J-33019 Bearing Staking Tool set - J-33020 Pulley Puller - J-33022 Shaft Nut Socket - J-33023-A Puller Pilot - J-33024 Clutch Coil Installer Adapter - J-33025 Clutch Coil Puller Legs - J-33027 Clutch Hub Holding Tool - J-34614 Shaft Seal Protector - J-34992 Compressor Holding Fixture - J-34993 Cylinder Alignment Rods - J-35372 Support Block

Restraints

RESTRAINTS SPECIFICATION Substitute Special Tools Special Tools Described in This Manual SUZUKI Scan Tool (Tech 2 Kit) Scanner or Scan Tool NOTE: This kit includes the following items. 1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loop back connector, 11. Storage case, 12. Power supply

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Body & Accessories

SPECIAL TOOLS SPECIFICATION